The document discusses principles and practices of maintenance planning. It covers key topics like maintenance, planning concepts, types of planning, maintenance planning, objectives of maintenance planning, principles of maintenance, reliability, need for reliability in maintenance, failure pattern of equipment, and failure density. The main points are:
- Maintenance ensures machines are kept in normal operating condition to deliver expected performance without damage.
- Planning ensures smooth system operation by converting concepts into actions like long, short, and immediate activity planning.
- Maintenance planning organizes resources to carry out jobs satisfactorily at reasonable cost within a specified time.
- Objectives include minimizing breakdowns and keeping plants in optimum working condition at lowest cost.
This document discusses various maintenance policies and strategies. It describes different types of maintenance tasks including breakdown maintenance, planned maintenance (preventive maintenance, corrective maintenance, predictive maintenance, condition-based maintenance, and reliability-centered maintenance). Preventive maintenance aims to eliminate breakdowns and deviations from optimal operating conditions. Predictive maintenance uses equipment operating data to optimize plant operations. Condition-based maintenance techniques include vibration monitoring, thermography, tribology, and electrical motor analysis. The document also covers lubrication methods like hydrostatic, hydrodynamic, boundary, and extreme pressure lubrication. Automatic lubrication systems include single line parallel, dual line parallel, single line progressive, mist lubrication, and multi-port direct lubrication systems.
This document provides an overview of mechanical components and maintenance for a Malaysian polytechnic handbook. It covers topics such as maintenance principles, procedures, lubrication, power transmission, bearings, clutches and brakes, pumps, valves and compressors. The document includes learning outcomes, definitions of maintenance, types of maintenance such as breakdown, preventive and predictive, and discusses safety practices, tools, costs and other aspects of maintenance. Chapters cover specific mechanical systems and components, how to inspect and maintain them, and develop maintenance procedures and checklists. Practical assemblies and disassemblies of components are also suggested as examples.
This document discusses repair and maintenance methods for various types of material handling equipment. It covers the objectives and need for maintenance of material handling equipment. Preventive maintenance techniques like inspection, repair, and overhaul are described. Specific maintenance strategies and schedules are provided for hoists and cranes, conveyors, forklifts, and other miscellaneous equipment. The importance of a systems approach to maintenance management is also highlighted.
This document outlines the importance of maintenance for equipment and outlines objectives and types of maintenance systems. The key objectives of maintenance are to improve reliability, increase asset life, ensure operational readiness, enable safe production, prevent waste, and support more sophisticated automation. There are two main types of maintenance systems - repair maintenance which addresses breakdowns, and preventive maintenance which aims to prevent breakdowns. Effective maintenance planning and control involves scheduling work, controlling costs, maintaining staffing, and ensuring continuity of production and automation.
The document describes a case study applying reliability-centered maintenance (RCM) methodology to develop a maintenance plan for a steam-process plant in Egypt. The plant consists of a fire-tube boiler, feed-water pump, dryers, and process heater. A failure mode and effect analysis was conducted for critical equipment. The boiler and pump were found to be critical. An RCM-based maintenance program was developed that decreased labor costs by 25.8% and downtime costs by 80% compared to the plant's current maintenance.
The document provides information on maintenance principles and procedures. It discusses the definition of maintenance as activities to keep systems functioning. The principles of maintenance are to achieve quality, maximize equipment life, and minimize interruptions. Planned maintenance includes activities like preventative maintenance to condition-based maintenance. Unplanned maintenance refers to emergency or breakdown maintenance. Maintenance aims to improve aspects like capacity, quality, and productivity while reducing costs and inventory. Workplace safety topics covered include personal protective equipment, lockout/tagout procedures, hazardous materials and energy, and the importance of inspecting hand tools and power tools.
This document discusses different types of maintenance for plants and equipment. It describes planned maintenance which includes preventive, corrective, and predictive maintenance. Preventive maintenance is carried out at predetermined intervals to reduce failures and includes running, scheduled, and shutdown maintenance. Corrective maintenance is performed after a failure to address the source of the problem. The key difference between preventive and corrective maintenance is timing - preventive is before and corrective is after a problem.
This document discusses various maintenance policies and strategies. It describes different types of maintenance tasks including breakdown maintenance, planned maintenance (preventive maintenance, corrective maintenance, predictive maintenance, condition-based maintenance, and reliability-centered maintenance). Preventive maintenance aims to eliminate breakdowns and deviations from optimal operating conditions. Predictive maintenance uses equipment operating data to optimize plant operations. Condition-based maintenance techniques include vibration monitoring, thermography, tribology, and electrical motor analysis. The document also covers lubrication methods like hydrostatic, hydrodynamic, boundary, and extreme pressure lubrication. Automatic lubrication systems include single line parallel, dual line parallel, single line progressive, mist lubrication, and multi-port direct lubrication systems.
This document provides an overview of mechanical components and maintenance for a Malaysian polytechnic handbook. It covers topics such as maintenance principles, procedures, lubrication, power transmission, bearings, clutches and brakes, pumps, valves and compressors. The document includes learning outcomes, definitions of maintenance, types of maintenance such as breakdown, preventive and predictive, and discusses safety practices, tools, costs and other aspects of maintenance. Chapters cover specific mechanical systems and components, how to inspect and maintain them, and develop maintenance procedures and checklists. Practical assemblies and disassemblies of components are also suggested as examples.
This document discusses repair and maintenance methods for various types of material handling equipment. It covers the objectives and need for maintenance of material handling equipment. Preventive maintenance techniques like inspection, repair, and overhaul are described. Specific maintenance strategies and schedules are provided for hoists and cranes, conveyors, forklifts, and other miscellaneous equipment. The importance of a systems approach to maintenance management is also highlighted.
This document outlines the importance of maintenance for equipment and outlines objectives and types of maintenance systems. The key objectives of maintenance are to improve reliability, increase asset life, ensure operational readiness, enable safe production, prevent waste, and support more sophisticated automation. There are two main types of maintenance systems - repair maintenance which addresses breakdowns, and preventive maintenance which aims to prevent breakdowns. Effective maintenance planning and control involves scheduling work, controlling costs, maintaining staffing, and ensuring continuity of production and automation.
The document describes a case study applying reliability-centered maintenance (RCM) methodology to develop a maintenance plan for a steam-process plant in Egypt. The plant consists of a fire-tube boiler, feed-water pump, dryers, and process heater. A failure mode and effect analysis was conducted for critical equipment. The boiler and pump were found to be critical. An RCM-based maintenance program was developed that decreased labor costs by 25.8% and downtime costs by 80% compared to the plant's current maintenance.
The document provides information on maintenance principles and procedures. It discusses the definition of maintenance as activities to keep systems functioning. The principles of maintenance are to achieve quality, maximize equipment life, and minimize interruptions. Planned maintenance includes activities like preventative maintenance to condition-based maintenance. Unplanned maintenance refers to emergency or breakdown maintenance. Maintenance aims to improve aspects like capacity, quality, and productivity while reducing costs and inventory. Workplace safety topics covered include personal protective equipment, lockout/tagout procedures, hazardous materials and energy, and the importance of inspecting hand tools and power tools.
This document discusses different types of maintenance for plants and equipment. It describes planned maintenance which includes preventive, corrective, and predictive maintenance. Preventive maintenance is carried out at predetermined intervals to reduce failures and includes running, scheduled, and shutdown maintenance. Corrective maintenance is performed after a failure to address the source of the problem. The key difference between preventive and corrective maintenance is timing - preventive is before and corrective is after a problem.
This document discusses various types of mechanical maintenance including preventive, corrective, operational, and lubrication maintenance. Preventive maintenance aims to maximize equipment availability and minimize defects by addressing potential issues before they arise. Corrective maintenance repairs equipment after failures occur. Operational maintenance includes inspecting, cleaning, and minor adjustments. Regular lubrication is important as it can decrease early bearing failures and increase bearing life. Proper maintenance helps keep equipment safe, reliable, and productive while avoiding high costs of unexpected breakdowns.
Reliability centered maintenance (RCM) integrates different maintenance strategies including reactive, preventive, predictive testing and inspection, and proactive maintenance. The goal of RCM is to maximize reliability and minimize maintenance costs and downtime. RCM involves analyzing systems to understand failures, prioritizing failures based on consequences, and determining the best strategy to address each failure. Common applications of RCM include the aviation, spacecraft, nuclear, and defense industries where minimizing downtime is critical.
The document discusses maintenance management and provides definitions of key terms. It describes the evolution of maintenance from simply fixing equipment when it breaks to more modern approaches like reliability centered maintenance (RCM). The objectives of maintenance are to preserve asset functions and avoid failures. The functions of maintenance management include physical asset management, maintenance strategy determination, and planning and scheduling maintenance work. Different maintenance strategies like preventative maintenance and condition-based maintenance are also covered.
TabWare is preventive maintenance software that provides a single platform for planning, organizing, and managing all preventive maintenance work including building maintenance plans, linking equipment, and scheduling work orders. It helps maximize asset performance and reduces unplanned downtime by providing the first line of defense against failures through detection of issues, lubrication, and replacement of wear parts. The software supports reliability centered maintenance programs and lean/total productive maintenance initiatives.
If you want to help or donate please donate at my paypal:
dyokimura@gmail.com
Credits:
NJM
MM
SUPPORT ME:
https://www.buymeacoffee.com/dyokimura6
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https://www.youtube.com/channel/UCoKOObshfyyxhVkw1VjyQNA
The document discusses the maintenance management activities at Shahi Exports Unit 12. It outlines the planning, maintenance, and improvement activities carried out by the maintenance department. The department plans machinery in advance, arranges machines for batch setting, and provides work aids to enhance productivity. It aims to reduce downtime and maintain machines in good working condition through scheduled maintenance. The department also coordinates with other departments on future styles and product requirements. The overall goal is to improve processes through methods like Total Productive Maintenance which focuses on continuous improvement, employee involvement, and measurement of results.
Maintenance management in operations managementShereen Shahana
Maintenance is the process of keeping machines and equipment in good working condition through actions like inspection, repair, overhaul, and lubrication. The goals are to retain efficiency, increase equipment life, and prevent breakdowns. There are different maintenance approaches - breakdown maintenance only repairs equipment after failures, while preventive maintenance inspects weak points regularly to avoid issues. Scheduled maintenance follows supplier recommendations and predetermined schedules. Proper maintenance provides benefits like increased equipment life, on-schedule production, quality products, and reduced costs and accidents.
This document discusses maintenance management systems at a garment manufacturing company. It outlines the objectives of maintenance management which are to create a safe work environment with zero waste and accidents while achieving 100% efficiency. The types of maintenance covered are routine, preventive, and emergency maintenance. The document then describes the maintenance organization structure and functions. Key elements of maintenance management discussed include maintenance policies, preventive maintenance, condition monitoring, work orders, and performance measurement. The maintenance department is divided into four sub-departments: central maintenance, batch maintenance, folders and fabrication, and utility and safety. The roles and maintenance approaches of each sub-department are summarized. Associated production planning and industrial engineering departments are also outlined.
Aviation maintenance methods asci609 final presentation_gstampGregory Stamp
This document outlines an aviation maintenance methodology that takes a multi-disciplinary approach by integrating Reliability-Centered Maintenance (RCM), Total Productive Maintenance (TPM), and Strategic Maintenance Management (SMM). RCM uses logical analysis to determine preventative maintenance requirements. TPM involves all employees in continuous improvement efforts. SMM incorporates maintenance into long-term strategic planning. Taken together, these methods aim to improve effectiveness, reduce costs, and minimize failures across aviation maintenance programs.
Plant maintenance involves methods and practices to keep industrial facilities running efficiently, including regular equipment checks, cleaning, and safety measures. Poor maintenance can negatively impact productivity. The maintenance process involves documenting equipment conditions, planning and executing maintenance tasks, and recording maintenance history. There are different types of maintenance approaches ranging from breakdown/corrective maintenance to preventive maintenance and proactive strategies like total productive maintenance (TPM), which aims to eliminate waste and involve employees to improve equipment reliability and productivity. TPM's five pillars are focused equipment management, autonomous maintenance, planned maintenance, quality maintenance, and safety and health. TPM differs from total quality management (TQM) in its emphasis on equipment and processes rather than only products and services.
The aim of this guide is to furnish Engineers, Technicians, Supervisors and Managers (that are involved in maintenance activities & planning) with a tool which equips them with technical data and information, often required for effective Maintenance works (especially on Valves); with applications in other areas, such as maintenance of: Pipelines, Pumps, Actuators, Wellhead Equipments etc. Sure you’d find this material useful.
1) The document outlines the preventive maintenance program of Al Ayuni Investment and Contracting Company. It defines preventive maintenance and describes the goals of avoiding equipment failure and unplanned downtime.
2) Details of the planning, implementation, and documentation processes are provided. Formats for maintenance scheduling, part requirements, and task tracking are referenced.
3) Requirements for equipment, tools, and dedicated personnel are listed to properly support the preventive maintenance of all company assets. This includes service trucks, stations, and a separate vehicle for greasing tasks.
Maintenance management involves planning and coordinating resources to ensure industrial equipment operates effectively at specified availability levels. It aims to minimize downtime and production losses through planned repair and preventative maintenance. There are different types of maintenance systems like corrective, preventative, and predictive maintenance. The bathtub curve model describes failure rates over equipment lifespan from initial high failure through useful life of constant rate to increasing wear out failures. Key activities involve scheduling maintenance, repairs, inspections, budgeting, and developing maintenance procedures, records, and staff training.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
This document discusses maintenance management and related topics. It begins with an introduction to maintenance and its importance in manufacturing. It then covers:
- Types of maintenance including preventive, total productive, and predictive maintenance.
- Key maintenance metrics like equipment effectiveness, losses, maintainability, reliability, and availability.
- Causes of equipment problems like deterioration, improper use, lack of maintenance, and operator errors.
- The objectives and organization of maintenance departments.
- Terminology used in maintenance management.
The document provides an overview of maintenance best practices and performance metrics for optimizing equipment uptime and minimizing production losses.
This document contains questions and answers related to maintenance engineering. It is divided into 5 units covering topics like maintenance planning, maintenance policies, condition monitoring, repair methods for machine elements, and repair methods for material handling equipment. Some of the key questions addressed include the objectives of maintenance organization and different types of organizations, types and classes of maintenance costs, steps in preventive maintenance and its benefits over reactive maintenance, distinguishing fixed time and condition-based maintenance, wear debris analysis techniques, failure analysis development, and maintenance procedures for various material handling equipment.
This document summarizes the vocational training that Ashish Chaudhary received at Jindal Steel and Power Limited in Raipur from June 10-July 10, 2014. It provides an overview of preventive, corrective, and reliability-centered maintenance approaches. It also describes various machines used in the plant such as lathes, milling machines, boring machines, and the maintenance required for lathe operations including adjusting drive belts, gibs, and end gearing.
The plant maintenance module provides an integrated solution to support enterprise-wide maintenance needs. It includes products to manage all aspects of plant and equipment maintenance. The module provides technical and business reports to help reduce plant downtime and recognize weak points in the technical system. The major subsystems include preventive maintenance control, equipment tracking, component tracking, calibration tracking, and warranty claims tracking. Preventive maintenance control allows planning, scheduling, and monitoring of equipment lubrication, replacement, and safety inspections. Equipment tracking monitors and protects assets, while component tracking identifies chronic repair problems. Calibration tracking supports ISO 9000 requirements and warranty claims tracking recovers reimbursements by managing warranty information.
This document discusses principles and practices of maintenance planning and condition monitoring. It defines key maintenance terms like maintenance, reliability, failure rate, mean time to failure, and discusses reliability analysis, predictive maintenance, and condition based monitoring techniques. The document also covers maintenance policies, preventive maintenance approaches, total productive maintenance, and repair methods for machine elements.
The document discusses key concepts in maintenance engineering including:
1. Definitions of maintenance, reliability, failure rate, mean time to failure, mean time between failures, and mean time to repair.
2. The main types of reliability are inherent and achievable reliability.
3. Planned maintenance approaches include preventive maintenance, predictive maintenance, condition-based maintenance, corrective maintenance, and reliability-centered maintenance.
4. Total productive maintenance aims to increase production while improving employee morale through a newly defined maintenance program.
This document discusses various types of mechanical maintenance including preventive, corrective, operational, and lubrication maintenance. Preventive maintenance aims to maximize equipment availability and minimize defects by addressing potential issues before they arise. Corrective maintenance repairs equipment after failures occur. Operational maintenance includes inspecting, cleaning, and minor adjustments. Regular lubrication is important as it can decrease early bearing failures and increase bearing life. Proper maintenance helps keep equipment safe, reliable, and productive while avoiding high costs of unexpected breakdowns.
Reliability centered maintenance (RCM) integrates different maintenance strategies including reactive, preventive, predictive testing and inspection, and proactive maintenance. The goal of RCM is to maximize reliability and minimize maintenance costs and downtime. RCM involves analyzing systems to understand failures, prioritizing failures based on consequences, and determining the best strategy to address each failure. Common applications of RCM include the aviation, spacecraft, nuclear, and defense industries where minimizing downtime is critical.
The document discusses maintenance management and provides definitions of key terms. It describes the evolution of maintenance from simply fixing equipment when it breaks to more modern approaches like reliability centered maintenance (RCM). The objectives of maintenance are to preserve asset functions and avoid failures. The functions of maintenance management include physical asset management, maintenance strategy determination, and planning and scheduling maintenance work. Different maintenance strategies like preventative maintenance and condition-based maintenance are also covered.
TabWare is preventive maintenance software that provides a single platform for planning, organizing, and managing all preventive maintenance work including building maintenance plans, linking equipment, and scheduling work orders. It helps maximize asset performance and reduces unplanned downtime by providing the first line of defense against failures through detection of issues, lubrication, and replacement of wear parts. The software supports reliability centered maintenance programs and lean/total productive maintenance initiatives.
If you want to help or donate please donate at my paypal:
dyokimura@gmail.com
Credits:
NJM
MM
SUPPORT ME:
https://www.buymeacoffee.com/dyokimura6
CHECK MY GAMING CHANNEL:
https://www.youtube.com/channel/UCoKOObshfyyxhVkw1VjyQNA
The document discusses the maintenance management activities at Shahi Exports Unit 12. It outlines the planning, maintenance, and improvement activities carried out by the maintenance department. The department plans machinery in advance, arranges machines for batch setting, and provides work aids to enhance productivity. It aims to reduce downtime and maintain machines in good working condition through scheduled maintenance. The department also coordinates with other departments on future styles and product requirements. The overall goal is to improve processes through methods like Total Productive Maintenance which focuses on continuous improvement, employee involvement, and measurement of results.
Maintenance management in operations managementShereen Shahana
Maintenance is the process of keeping machines and equipment in good working condition through actions like inspection, repair, overhaul, and lubrication. The goals are to retain efficiency, increase equipment life, and prevent breakdowns. There are different maintenance approaches - breakdown maintenance only repairs equipment after failures, while preventive maintenance inspects weak points regularly to avoid issues. Scheduled maintenance follows supplier recommendations and predetermined schedules. Proper maintenance provides benefits like increased equipment life, on-schedule production, quality products, and reduced costs and accidents.
This document discusses maintenance management systems at a garment manufacturing company. It outlines the objectives of maintenance management which are to create a safe work environment with zero waste and accidents while achieving 100% efficiency. The types of maintenance covered are routine, preventive, and emergency maintenance. The document then describes the maintenance organization structure and functions. Key elements of maintenance management discussed include maintenance policies, preventive maintenance, condition monitoring, work orders, and performance measurement. The maintenance department is divided into four sub-departments: central maintenance, batch maintenance, folders and fabrication, and utility and safety. The roles and maintenance approaches of each sub-department are summarized. Associated production planning and industrial engineering departments are also outlined.
Aviation maintenance methods asci609 final presentation_gstampGregory Stamp
This document outlines an aviation maintenance methodology that takes a multi-disciplinary approach by integrating Reliability-Centered Maintenance (RCM), Total Productive Maintenance (TPM), and Strategic Maintenance Management (SMM). RCM uses logical analysis to determine preventative maintenance requirements. TPM involves all employees in continuous improvement efforts. SMM incorporates maintenance into long-term strategic planning. Taken together, these methods aim to improve effectiveness, reduce costs, and minimize failures across aviation maintenance programs.
Plant maintenance involves methods and practices to keep industrial facilities running efficiently, including regular equipment checks, cleaning, and safety measures. Poor maintenance can negatively impact productivity. The maintenance process involves documenting equipment conditions, planning and executing maintenance tasks, and recording maintenance history. There are different types of maintenance approaches ranging from breakdown/corrective maintenance to preventive maintenance and proactive strategies like total productive maintenance (TPM), which aims to eliminate waste and involve employees to improve equipment reliability and productivity. TPM's five pillars are focused equipment management, autonomous maintenance, planned maintenance, quality maintenance, and safety and health. TPM differs from total quality management (TQM) in its emphasis on equipment and processes rather than only products and services.
The aim of this guide is to furnish Engineers, Technicians, Supervisors and Managers (that are involved in maintenance activities & planning) with a tool which equips them with technical data and information, often required for effective Maintenance works (especially on Valves); with applications in other areas, such as maintenance of: Pipelines, Pumps, Actuators, Wellhead Equipments etc. Sure you’d find this material useful.
1) The document outlines the preventive maintenance program of Al Ayuni Investment and Contracting Company. It defines preventive maintenance and describes the goals of avoiding equipment failure and unplanned downtime.
2) Details of the planning, implementation, and documentation processes are provided. Formats for maintenance scheduling, part requirements, and task tracking are referenced.
3) Requirements for equipment, tools, and dedicated personnel are listed to properly support the preventive maintenance of all company assets. This includes service trucks, stations, and a separate vehicle for greasing tasks.
Maintenance management involves planning and coordinating resources to ensure industrial equipment operates effectively at specified availability levels. It aims to minimize downtime and production losses through planned repair and preventative maintenance. There are different types of maintenance systems like corrective, preventative, and predictive maintenance. The bathtub curve model describes failure rates over equipment lifespan from initial high failure through useful life of constant rate to increasing wear out failures. Key activities involve scheduling maintenance, repairs, inspections, budgeting, and developing maintenance procedures, records, and staff training.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
This document discusses maintenance management and related topics. It begins with an introduction to maintenance and its importance in manufacturing. It then covers:
- Types of maintenance including preventive, total productive, and predictive maintenance.
- Key maintenance metrics like equipment effectiveness, losses, maintainability, reliability, and availability.
- Causes of equipment problems like deterioration, improper use, lack of maintenance, and operator errors.
- The objectives and organization of maintenance departments.
- Terminology used in maintenance management.
The document provides an overview of maintenance best practices and performance metrics for optimizing equipment uptime and minimizing production losses.
This document contains questions and answers related to maintenance engineering. It is divided into 5 units covering topics like maintenance planning, maintenance policies, condition monitoring, repair methods for machine elements, and repair methods for material handling equipment. Some of the key questions addressed include the objectives of maintenance organization and different types of organizations, types and classes of maintenance costs, steps in preventive maintenance and its benefits over reactive maintenance, distinguishing fixed time and condition-based maintenance, wear debris analysis techniques, failure analysis development, and maintenance procedures for various material handling equipment.
This document summarizes the vocational training that Ashish Chaudhary received at Jindal Steel and Power Limited in Raipur from June 10-July 10, 2014. It provides an overview of preventive, corrective, and reliability-centered maintenance approaches. It also describes various machines used in the plant such as lathes, milling machines, boring machines, and the maintenance required for lathe operations including adjusting drive belts, gibs, and end gearing.
The plant maintenance module provides an integrated solution to support enterprise-wide maintenance needs. It includes products to manage all aspects of plant and equipment maintenance. The module provides technical and business reports to help reduce plant downtime and recognize weak points in the technical system. The major subsystems include preventive maintenance control, equipment tracking, component tracking, calibration tracking, and warranty claims tracking. Preventive maintenance control allows planning, scheduling, and monitoring of equipment lubrication, replacement, and safety inspections. Equipment tracking monitors and protects assets, while component tracking identifies chronic repair problems. Calibration tracking supports ISO 9000 requirements and warranty claims tracking recovers reimbursements by managing warranty information.
This document discusses principles and practices of maintenance planning and condition monitoring. It defines key maintenance terms like maintenance, reliability, failure rate, mean time to failure, and discusses reliability analysis, predictive maintenance, and condition based monitoring techniques. The document also covers maintenance policies, preventive maintenance approaches, total productive maintenance, and repair methods for machine elements.
The document discusses key concepts in maintenance engineering including:
1. Definitions of maintenance, reliability, failure rate, mean time to failure, mean time between failures, and mean time to repair.
2. The main types of reliability are inherent and achievable reliability.
3. Planned maintenance approaches include preventive maintenance, predictive maintenance, condition-based maintenance, corrective maintenance, and reliability-centered maintenance.
4. Total productive maintenance aims to increase production while improving employee morale through a newly defined maintenance program.
This document outlines the syllabus for the ME2037 Maintenance Engineering course. The objectives are to understand maintenance principles, functions, and industry practices for successful management. Key topics covered include maintenance planning principles, preventive maintenance policies, condition monitoring methods and instruments, repair methods for machine elements and material handling equipment. Assessment includes understanding reliability concepts like MTBF, MTTR, and factors affecting availability. The course aims to explain different maintenance categories and illustrate condition monitoring instruments to manage maintenance activities effectively.
1. The document provides important questions and answers related to maintenance engineering for slow learners. It covers topics like condition monitoring, reliability analysis, failure rate, mean time to failure, and availability.
2. The maintenance organization structure and economics are explained in detail. Different types of maintenance organization like decentralized, centralized, and partially centralized are described. Factors considered for maintenance planning and life cycle cost analysis are also summarized.
3. Availability is defined as the ratio of time equipment is available to the total time of operation and maintenance. Different types of availability like inherent, achieved and operational availability are stated along with the formula to calculate inherent availability.
The document discusses principles and practices of maintenance planning. It covers topics like maintenance engineering, planning processes, objectives of planned maintenance, principles of maintenance systems, reliability measures like MTBF and MTTR, maintenance organization structures, and maintenance economics. The key aspects are ensuring smooth operations through planning, following principles to guide efficient maintenance work, benefits of sound maintenance systems for minimizing downtime and improving availability, and analyzing life cycle costs of equipment maintenance.
The document discusses principles and practices of maintenance planning in engineering systems. It describes key concepts like maintenance engineering, types of planning, objectives of planned maintenance, principles of maintenance systems, reliability measures like MTBF and MTTR, maintenance organization structures, and maintenance economics and costs. The overall goal of maintenance planning is to optimize equipment availability and performance at lowest cost through reliable maintenance strategies.
Development Of An Effective Industrial Maintenance Practice For Plant Optimum...IJERA Editor
Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The
decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum
performance not only enhances the plant operations, it quite often produces a safer operating facility and
protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment
and maintenance programs for an assured performance whiles strategies are required to be in place for
equipment optimum availability to ensure system operational integrity in order to reduce costs which affect
production. This optimized system would ideally give meaning to effective maintenance practice of plant
equipment and accepted best maintenance management system. This paper presents a comprehensive review of
characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance
management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the
environment. The goal is to achieve optimum availability and optimum operating condition of the equipment
life cycle in a cost optimized approach.
The document discusses various aspects of maintenance management including definitions, objectives, types of maintenance, reliability concepts, modern maintenance methods, and total productive maintenance pillars. It defines maintenance as work to keep equipment in proper working order and prevent failures. The main types of maintenance discussed are breakdown, preventive, and predictive maintenance. Modern maintenance methods include reliability centered maintenance, six sigma maintenance, and total productive maintenance.
Maintenance Engineering, Principle of Maintenancerishikantmip22
The document discusses maintenance engineering principles and practices. It covers objectives of maintenance planning which include maximizing production availability and minimizing costs. It also discusses reliability concepts such as MTBF, MTTR, and availability. Different types of maintenance organization structures are described such as decentralized, centralized, and partially centralized models. Key aspects of maintenance such as maintainability, availability calculations, and factors affecting them are explained.
Maintenance Lecture Notes for senior classNegash Alemu
The document provides an overview of maintenance engineering. It discusses different types of maintenance including preventive maintenance, which aims to avoid breakdowns by performing maintenance before issues occur. Corrective maintenance repairs equipment after a failure. The document outlines the objectives of maintenance as maximizing equipment performance, preventing failures, and minimizing downtime to increase production. Overall, the document introduces the key concepts and objectives of maintenance engineering.
The document discusses maintenance management. It defines maintenance as keeping equipment operational or repairing it. The objectives of maintenance are increased availability, safety, and optimized costs. Maintenance management involves managing maintenance functions. Common maintenance strategies discussed are breakdown, preventive, predictive, opportunity, and design-out maintenance. Functions of the maintenance department include maintaining equipment, installations, preventive maintenance, condition monitoring, modifications, inventory management, and record keeping. Elements of effective maintenance management discussed are maintenance policy, materials control, work orders, job planning, data recording, and performance measurement.
ME6012 ME UNIT 1 TO 5 - BY Civildatas.com pec.pdfSou Tibon
This syllabus outlines a course on Maintenance Engineering that covers key principles and practices of maintenance planning, different maintenance categories like preventive maintenance and condition monitoring, and repair methods for machine elements and material handling equipment. The objectives are to understand maintenance management principles, explain maintenance categories, and illustrate condition monitoring instruments. Key topics covered in the five units include maintenance planning principles and practices, preventive maintenance policies, condition monitoring methods, repair methods for machine elements, and repair of material handling equipment. Textbooks and references on topics like industrial maintenance, installation and servicing are also listed.
Maintenance of facilities and equipment is important to achieve high quality, reliability, and efficient operations. There are various types of maintenance including planned, preventive, corrective, and breakdown maintenance. The objectives of maintenance are to maximize equipment life, minimize costs, and ensure safety. An effective approach is condition-based maintenance which uses sensors and monitoring to predict failures before they occur. This improves system availability while reducing downtime and maintenance costs. Finally, proper planning and scheduling of maintenance jobs is important to efficiently execute repairs.
Maintenance of facilities and equipment is important to achieve high quality, reliability, and efficient operations. There are different types of maintenance including preventive maintenance, which helps keep equipment in good working condition, and breakdown maintenance, which is reactive repair when equipment fails. The objectives of maintenance are to maximize equipment life, minimize costs, and ensure safety. An effective approach is condition-based maintenance using sensors to monitor equipment condition and predict failures so they can be addressed before causing downtime.
Maintenance of facilities and equipment is important to achieve quality, reliability and efficiency. The objectives of plant maintenance are to increase reliability, maximize equipment life, minimize costs, and enhance safety. Preventive maintenance helps reduce downtime costs which usually exceed costs of inspection and service. An effective maintenance program requires trained staff, regular inspection and service, and record keeping. The goal is to prevent failures through planned activities rather than relying on expensive emergency repairs after breakdowns.
Industrial Engineering unit 4.Production planning and control Notes by badebhau.Er. Bade Bhausaheb
Production planning and control aims to efficiently and effectively manage operations in a manufacturing organization. It addresses issues like low productivity, inventory management, and resource utilization. The key objectives of production planning and control are to optimize capacity utilization, maintain optimal inventory levels, minimize costs, and ensure quality. Production planning involves determining what to produce, when, how much, and other long-term decisions. Production control techniques are used to achieve production planning targets by regulating inventory, scheduling production, and optimizing resource usage.
This document discusses the importance of maintenance for companies. It defines maintenance as any activity carried out to keep facilities in good working condition. The goals of maintenance are to minimize breakdowns, keep equipment operating at optimal capacity, and ensure availability. Without proper maintenance, equipment will break down more often and quality and output will suffer. The document outlines the primary and secondary functions of maintenance engineering and stresses that maintenance should be effectively managed throughout the entire lifecycle of equipment from design to replacement.
This document provides an overview of a training on industrial plant machineries troubleshooting and maintenance taking place on February 8, 2023 in Lagos, Nigeria. The training will cover preventive maintenance management and machinery/equipment overview. Module one will discuss maintenance concepts, solving equipment failures/losses, and presenting maintenance challenges. The goals are to explain maintenance management, solve manufacturing process problems, and submit a maintenance management report.
This document discusses reliability centered maintenance (RCM) and predictive maintenance strategies. It focuses on a case study of ABC Automobile Company which currently uses preventive maintenance involving manual condition monitoring. The document aims to evaluate if RCM and predictive maintenance using vibration monitoring could improve maintenance effectiveness for rotating equipment. It outlines the existing condition monitoring process, identifies gaps in the current approach, and proposes analyzing equipment parameters to predict failures. A test case will analyze a proposal to identify root causes of performance decline and determine optimal maintenance timing before failures occur.
This document discusses reliability centered maintenance (RCM) and predictive maintenance strategies. It focuses on a case study of ABC Automobile Company which currently uses preventive maintenance involving manual condition monitoring. The document aims to evaluate if RCM and predictive maintenance using vibration monitoring could improve maintenance effectiveness for rotating equipment. It outlines the existing condition monitoring process, identifies gaps in the current approach, and proposes analyzing equipment parameters to predict failures. A test case will analyze a proposal to identify root causes of performance decline and determine optimal maintenance timing before failures occur.
This document discusses common rail direct injection (CRDI) engines. It notes that CRDI engines were developed to overcome problems with conventional diesel engines like poor atomization of fuel. CRDI engines use a common rail system that can maintain very high fuel pressures, up to 1800 bar, to improve atomization. This high-pressure fuel is distributed to electronically controlled injectors. The injectors are precisely timed by an engine control unit to optimize fuel delivery for each cylinder based on operating conditions. CRDI engines have benefits like lower emissions and improved fuel economy compared to conventional diesel engines.
This document provides information on various repair methods for machine elements and components. It discusses repair techniques for machine beds including riveting and clamping cracks. It also covers repair of slideways through scraping, grinding and machining. Methods for repairing gears, bearings and other components are described. Failure analysis techniques like fault tree analysis and event tree analysis are also summarized.
This document discusses various techniques for condition monitoring including visual inspection using mirrors, borescopes, and endoscopes. It also discusses vibration monitoring using time and frequency domain analysis, temperature monitoring using thermometers and infrared thermography, lubricant monitoring using spectroscopic analysis and filter debris analysis, wear monitoring using optical and magnetic methods, crack monitoring using liquid penetrant testing and eddy current testing, leakage monitoring using acoustic and gas detection methods, and corrosion monitoring using weight loss measurement and corrosion potential analysis.
This document discusses advances in metrology, specifically interferometry. It begins by introducing concepts of light as a wave and key wave properties. It then discusses the principles and types of interference that occur when light waves interact or overlap, including constructive and destructive interference. Interferometry techniques are used to determine the size of standards directly in terms of the wavelength of light. Types of interferometers are also summarized, including the Michelson interferometer and single frequency DC interferometer system. Lasers are discussed as a coherent light source used for improved interferometry measurements.
This document discusses various methods for measuring force, torque, power, flow, temperature, and their reliability and calibration. It describes direct and indirect force measurement techniques including equal arm balances, load cells, strain gauges, and accelerometers. It also outlines torque measurement using prony brakes, strain gauges, and torsion bars. Methods for measuring power, flow, and temperature are presented including dynamometers, orifice meters, venturimeters, thermocouples, and pyrometers. The document concludes with definitions and descriptions of reliability, calibration, readability, and reliability.
Screw threads are used to fasten components and transmit motion or power. There are various types of screw threads classified by their form, included angle, and other geometric properties. Common thread types include British Standard, Whitworth, and metric threads. Screw thread geometry includes features like the crest, flanks, root, pitch, helix angle, and diameters. Errors in screw threads can occur during manufacturing and affect the thread form and fit. Measurement of screw threads involves determining dimensions like the major diameter, minor diameter, effective or pitch diameter, and pitch using instruments like micrometers, thread comparators, and slip gauges.
Linear and angular measurements are fundamental concepts in metrology. There are several precision tools used for linear measurements, including rulers, vernier calipers, and micrometers. Vernier calipers use a vernier scale to measure lengths with an accuracy of 0.02mm or better. Micrometers can measure with an accuracy of 0.01mm or better using a screw mechanism. Other important linear measuring tools discussed include slip gauges, height gauges, and depth gauges. Angular measurements are also important and were historically used for navigation.
This document discusses factors to consider when selecting measuring instruments, including sensitivity, hysteresis, range, span, response time, repeatability, accuracy, precision, magnification, stability, resolution, error, drift, reliability and more. It describes types of errors such as static errors, dynamic errors, systematic errors and random errors. Methods to reduce errors from the environment, supports, alignment, dirt, vibrations, wear and other sources are provided. The history of measurement standards from ancient Egypt is briefly mentioned.
Sri Guru Hargobind Ji - Bandi Chor Guru.pdfBalvir Singh
Sri Guru Hargobind Ji (19 June 1595 - 3 March 1644) is revered as the Sixth Nanak.
• On 25 May 1606 Guru Arjan nominated his son Sri Hargobind Ji as his successor. Shortly
afterwards, Guru Arjan was arrested, tortured and killed by order of the Mogul Emperor
Jahangir.
• Guru Hargobind's succession ceremony took place on 24 June 1606. He was barely
eleven years old when he became 6th Guru.
• As ordered by Guru Arjan Dev Ji, he put on two swords, one indicated his spiritual
authority (PIRI) and the other, his temporal authority (MIRI). He thus for the first time
initiated military tradition in the Sikh faith to resist religious persecution, protect
people’s freedom and independence to practice religion by choice. He transformed
Sikhs to be Saints and Soldier.
• He had a long tenure as Guru, lasting 37 years, 9 months and 3 days
This study Examines the Effectiveness of Talent Procurement through the Imple...DharmaBanothu
In the world with high technology and fast
forward mindset recruiters are walking/showing interest
towards E-Recruitment. Present most of the HRs of
many companies are choosing E-Recruitment as the best
choice for recruitment. E-Recruitment is being done
through many online platforms like Linkedin, Naukri,
Instagram , Facebook etc. Now with high technology E-
Recruitment has gone through next level by using
Artificial Intelligence too.
Key Words : Talent Management, Talent Acquisition , E-
Recruitment , Artificial Intelligence Introduction
Effectiveness of Talent Acquisition through E-
Recruitment in this topic we will discuss about 4important
and interlinked topics which are
Supermarket Management System Project Report.pdfKamal Acharya
Supermarket management is a stand-alone J2EE using Eclipse Juno program.
This project contains all the necessary required information about maintaining
the supermarket billing system.
The core idea of this project to minimize the paper work and centralize the
data. Here all the communication is taken in secure manner. That is, in this
application the information will be stored in client itself. For further security the
data base is stored in the back-end oracle and so no intruders can access it.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Build the Next Generation of Apps with the Einstein 1 Platform.
Rejoignez Philippe Ozil pour une session de workshops qui vous guidera à travers les détails de la plateforme Einstein 1, l'importance des données pour la création d'applications d'intelligence artificielle et les différents outils et technologies que Salesforce propose pour vous apporter tous les bénéfices de l'IA.
Determination of Equivalent Circuit parameters and performance characteristic...pvpriya2
Includes the testing of induction motor to draw the circle diagram of induction motor with step wise procedure and calculation for the same. Also explains the working and application of Induction generator
Accident detection system project report.pdfKamal Acharya
The Rapid growth of technology and infrastructure has made our lives easier. The
advent of technology has also increased the traffic hazards and the road accidents take place
frequently which causes huge loss of life and property because of the poor emergency facilities.
Many lives could have been saved if emergency service could get accident information and
reach in time. Our project will provide an optimum solution to this draw back. A piezo electric
sensor can be used as a crash or rollover detector of the vehicle during and after a crash. With
signals from a piezo electric sensor, a severe accident can be recognized. According to this
project when a vehicle meets with an accident immediately piezo electric sensor will detect the
signal or if a car rolls over. Then with the help of GSM module and GPS module, the location
will be sent to the emergency contact. Then after conforming the location necessary action will
be taken. If the person meets with a small accident or if there is no serious threat to anyone’s
life, then the alert message can be terminated by the driver by a switch provided in order to
avoid wasting the valuable time of the medical rescue team.
2. MAINTENANCE
Maintenance is the routine and recurring process
of keeping a particular machine or asset in its normal
operating condition so that it can deliver the expected
performance or service without any loss or damage.
2
The responsibility of the maintenance function should
be to ensure that production equipment/facilities are
available for use for maximum time at minimum cost
within stipulated time period.
3. 3
CONCEPT OF PLANNING
Planning ensures the smooth operation of the system. For effective
working of any system, it is necessary to plan and schedule its activities.
The basic objectives of any planning task are to convert the concepts
into workable actions.
There are several approaches in planning which are necessary to fulfill the objectives of
organization. The planning in engineering system is classified into three major approaches:
• Long range Planning
• Short range Planning and
• Planning for immediate activity
Long Range Planning
Long range planning refers to the planning spread over span of five to ten years. In this type
of planning the goals are set, strategies are developed and operational programmed are
devised for the period of planning.
Short Range Planning
Short range planning is prepared by the concerned departments for a relatively shorter period
of time say one to two years.
Immediate Activity Planning
Immediate activity planning is a routine and is done at the working level as and when
required.
4. MAINTENANCE PLANNING
Maintenance planning is the task of organizing
resources to carry out a job satisfactorily at
reasonable cost within a specified period of time.
4
5. 5
Objectives of Maintenance Planning
The most important objective of the maintenance system is the maximization of availability
of equipments and facilities so as to help in achieving the ultimate goals of the
organization. The following are the objectives of planned maintenance activity:
(i) To achieve minimum breakdown and to keep the plant in good working condition at the
lowest possible cost
(ii) To ensure the availability of the machines and services in an optimum working condition
(iii) To keep the Machines and other facilities in a condition to be used to achieve the
maximum profit without any interruption or hindrance
(iv) To keep the time schedule of delivery to the customers or to the sections for further
processing
(v) To meet the availability requirements for critical equipments
(vi) To keep the maintenance costs as low as possible for non critical equipments
(vii) To control the cost of maintenance related activities
(viii) To provide effective and trained supervision
(ix) To meet the quality requirements of the product.
(x) To increase the profits of production systems.
6. 6
PRINCIPLES OF MAINTENANCE
The main areas of work governed by these principles are:
(i) Plant Management in Maintenance work
The main role of the maintenance function is to provide safe and effective
operation of the equipment to achieve the desired targets on time with economic usage of
resources.
(ii) Production and Maintenance objectives
The plant operation is driven by the production targets. The objective of
maintenance function is to support these targets. The achievement of desired goals of the
production system is to be supported by both the production and maintenance department to
ensure smooth and successful operation of the industry.
(iii) Establishment of Work order and Recording system
The maintenance system should have proper work order and recording
system. The work order for the maintenance function indicates the nature of work to be
performed and the series of operations to be followed to execute a particular job
(iv) Information Based Decision Making
The maintenance objectives are successfully achieved by the use of reliable
information system. This information is used to meet the manpower and spare parts
requirements of the industry.
(v) Adherence to Planned Maintenance Strategy
A sound maintenance management should adhere to the planned maintenance strategy. This also
includes the use of manufacturer's information on the life and maintenance schedules of the equipment and other
material resources available.
7. 7
(vi) Planning of Maintenance Functions
All the maintenance functions are to be carefully executed by a way of proper planning
to ensure the effective utilization of manpower and materials.
(vii) Manpower for Maintenance
The manpower requirements of the maintenance system must be carefully evaluated
based on the time and motion study. The requirements should also satisfies the need arising in
cases of overhauls, component replacement, emergency and unscheduled repairs.
(viii) Workforce Control
Determination of exact workforce required to meet the maintenance objectives of the
system is difficult task due to the element of uncertainty. Hence the proper control and
monitoring of workforce are needs to be ensured.
(ix) Role of Spare Parts
A good maintenance management system requires appropriate tools. So the system
should have good quality tools and that too available in required quantities to ensure the proper
function of the maintenance works.
(x) Training of the Maintenance Workforce
Training of the workforce must be integral part of any good maintenance management
system. Training helps the workforce to learn about the modem techniques, recent trends in
maintenance, knowledge of sophisticated instruments and to chalk out a strategy to meet the
growing demands of the industry.
8. 8
SOUND MAINTENANCE MANAGEMENT SYSTEM
The profit of any industry depends solely on the return on the investment. The capital cost
and operating costs are the major factors involved in any industrial investment. The life of
the equipment and maintenance schedule information provided by manufacturer may not
realized in practice to make the need for having a sound management system.
The following are the benefits of sound maintenance management system:
(i) Minimization of down time
(ii) Improvement in availability of system
(iii) Extended life of equipment
(iv) Safety and smooth operation of the process
(v) Provide adequate back up supply
(vi) Minimization of normal expected wear and tear of equipment
(vii) Safety of the personal involved in the organization
(viii) Increased reliability of the system
(ix) Provide proper working environment
(x) Cost effective maintenance boost the profit of the production system
9. 9
RELIABILITY
The concept of reliability has found increased use in industrial engineering maintenance
and management. The reliability of any engineering system is based on the reliability of product,
equipment and various components of the system. The application of reliability techniques to
any equipment helps to identify the flaws in system design, compare several possible
configurations, minimize downtime, maximize operational readiness, reduce operating costs and
develop maintenance policies.
NEED FOR RELIABILITY IN MAINTENANCE
The reliability of a system, equipment, and product is very important aspect of quality for its
consistent performance over its expected life span. In case of sudden failure in anyone
component, the entire assembly or system results in loss of production, may cause potential
health hazard, accident and interruption in continuity of service
Examples include electric power generation and distribution system, process plants, aero plane.
automobile vehicles, etc.
Reliability is defined as the probability that a component/system. when operating under given
condition, will perform its intended functions adequately for a specified period of time. It refers
to the like hood that equipment will not fail during its operation. The four important factors
required in the determination of reliability are:
(i) Reliability expressed as probability (ii) Adequate performance requirements
(iii) Duration of adequate perfomance (iv) Environmental or operating conditions
10. 10
(i) Reliability Expressed as Probability
Probability is the ratio of the number of times we can expect an event to occur to the
total number of trials undertaken. A reliability factor can be expressed as probability. A
reliability factor equal to one means that device performs satisfactorily for the prescribed
duration under the given environmental condition. A reliability factor of zero means that all
cases the equipment would fail to meet the required performance level.
(ii) Adequate Performance Requirements
This defines the role expected of a device or system. A system may perform
satisfactorily even though one or more components may not be functioning. In reliability analysis
there is a need to define the magnitude of satisfactory or adequate performance of the system.
(iii) Duration of Adequate Performance
The duration of adequate performance is used to state the time up to which the desired
performance of the system is achieved under the given operating conditions.
(iv) Environmental or Operating Conditions
Environmental conditions indicate the prevailing.' conditions at which the system is
under operation.
11. 11
FAILURE PATTERN OF EQUIPMENT
The failure pattern of equipment over its whole life cycle can be
represented as shown in Figure
In Phase 1
The failure pattern inherent in a new product because of manufacturing or design defects.
This is refereed to as infant mortality period of equipment.
Phase II
shows the useful life period of an equipment where the failures rates are normally moderate as
the equipment gets set to the working environment.
In Phase III,
the failures are occurring due to wear out failures that are caused due to aging of the equipment.
The equipment life cycle is the essential requirement for the prediction of system reliability. The
other important parameters such as repair time distribution can be used to estimate availability,
maintainability and level of corrective and preventive maintenance.
12. 12
Failure Density
Failure density is the ratio of the number of failures during a given unit interval of time to the
total number of items at the very beginning of the test. Let n1 be the number of components that
fail during the first unit interval, n2 be the number that fail during the second unit interval and so
on. Let there are N population.
13. 13
Failure Rate (Z)
Failure rate is the ratio of the number of failures during particular unit interval to the average
population during that interval. This failure rate is also known as hazard rate and instantaneous
failure rate.
Reliability (R)
Reliability is the probability of a device performing its purpose adequately for the period in
tenaed under the given operating conditions .Reliability is the ratio of the survivors at any given
time to the total initial population.
Reliability Model
A basic measurement of the reliability of the product i.e., its probability of survival is that of
mean time between failures. Suppose that n products are taken at random from a large group and
let nt of them fail during the time period t. Then the probability of failure during the period t is
given by P =nt /n
It is necessary to evaluate the performance of the product over the intended length of time T for
the determination of reliability. Then
Reliability = 1- Probability of Failure
15. 15
PROBABILITY OF FAILURE
The probability of failure is the ratio of the number of units that failed at specified period of time
to the total population.
Mean Failure Rate (h)
The mean failure rate h is obtained by finding the mean of the failures rates for specified period
of time.
Where Z7 represents failure rates over the specified period of time
Mean Time to Failure (MTTF)
Let t1is the time to failure for the first specimen, t2 is the time to failure for the second specimen
and t n is the time to failure for the Nth
specimen. Hence the mean time to failure for N specimens
are
It is difficult to record the failure for each component when the numbers of specimens tested are
large. Instead. we can record the number which fails during the specific intervals of time.
If n1 is the number of specimens that failed during the first hour, n2 is the number that failed
during the second hour and nk is the number that failed during the kill hour. Then the mean time
to failure for N 'specimens is MTTF = (n l + 2n2 + 3n3 + + k nk ) / N
It is better to represent the time as interval instead of the time as such as. Hence the time interval
is ∆ t instead of one hour.
16. 16
Mean Time Between Failures (MTBF)
Mean Time Between Failures (MTBF) is the mean or average time between successive failures
of a product. Mean time between failures refers to the average time of breakdown until the device
is beyond repair.
Mean Time to Repair (MTTR)
Mean Time to repair (MTTR) is the arithmetic mean of the time required to perform maintenance
action. MTTR is defined as the ratio of total maintenance time and number of
maintenance action.
Maintenance Action Rate
Maintenance action rate is the number of maintenance action that can be carried out on
equipment per hour.
17. 17
1.2.5. TYPES OF RELIABILITY
Reliability can be generally of two types
1. Inherent Reliability
It is associated with the quality of the. material and design of
machine parts.
2. Achievable Reliability
It depends upon other factors such as maintenance and operation of
the equipment.
1.2.6. SERIES RELIABILITY MODEL
In this model, the components are arranged in series and the success of the system depends on
the success of all of its components. Consider the reliability model as shown in Figure 1.6 in
which n
components having reliabilities as R1, R2, •••.• Rn are connected in series .In this system, the
failure of any component puts the complete system in down position. The reliability of the
complete system would be Rs = R1 X R2 X R3 X ••.•.• X R n
.
18. 18
PARALLEL RELIABILITY MODEL
In this model, the system can be partially operative even if some of its components are in the
state of failure. Consider the reliability model as shown in Figure. in which n components
having reliabilities as R1 R2 •.•... Rn are connected in parallel. The total system reliability can
be
calculated by the product law of unreliability of the system.
The overall system is given by
PARALLEL RELIABILITY MODEL
19. 19
SERIES-PARALLEL RELIABILITY MODEL
In practice, more complex configurations exist where components are arranged in series and
parallel. The reliability structure of such complex system is decomposed into simpler structures
through successive application of the conditional probability theorem. The reliability of the
system can be determined from the failure probability of the arrangement as a consequence of
Let us consider the arrangement as shown in Figure If R1, R2, R3 and R4 be the reliabilities of
units 1,2,3 and 4 respectively. Failure of R, R2 is expressed a s ( l-probability of reliability).
Thus
The increasing complexity of present day equipment maintenance management has brought into
focus two other aspects known as maintainability and availability, both of them are closely
related to reliability.
20. 20
Maintenance and Reliability
The total reliability of any equipment is a function of design, maintenance and
field operational reliability. RF = f( D, M, FO)
MAINTAINABILITY
Maintainability is defined as the probability that a unit or system will be restored to
specified working conditions within a given period when maintenance action is taken in
accordance with the prescribed procedures and resources. Maintainability is also expressed in
terms of the minimum cost of maintenance as well as the accuracy of the maintenance functions.
The numerical value of maintainability lies between zero and one.
AVAILABILITY
Availability is the-ratio of the time at which equipment is available for the designated
operation/service to the total time of operation and maintenance of the equipment.
It is also defined as the ratio of equipments uptime to the equipment uptime and
downtime over a specified period of time. The uptime of a machine/equipment is the time for
which it is in actually available to complete the desired function.
The downtime or outage of a machine is the period of time during which it is not in an
acceptable working condition.
There are three types of availability are defined based on the time element. They are
(i) Inherent Availability
(ii) Achieved Availability
(iii) Operational Availability
21. 21
Inherent Availability
Inherent availability is the probability that a system or equipment shall operate
satisfactorily when used under prescribed conditions in an ideal support environment without any
scheduled or preventive maintenance at any given time,
Inherent Availability = MTBM / MTBM+MTTR
Ideal support environment means the ready availability of tools, spare pats, manpower,
manual, etc,
Achieved Availability
Achieved availability is the probability that a system or equipment shall operate satisfactorily
when used under prescribed conditions in an ideal support environment with periodic preventive
and corrective maintenance at any given time.
Achieved Availability = MTBM / MTBM+M
where M' is the mean active maintenance downtime resulting from preventive and corrective
maintenance
22. 22
Operational Availability
In Industrial system, a certain amount of delay will always caused by time element
such as supply downtime and administrative dowl1time.
Operational Availability is the probability that a system or equipment shall operate
satisfactorily when used under prescribed conditions in an actual supply environment without
any scheduled or preventive maintenance at any given time,
Operational Availability = ------MTBM / MTBM + MDT
where MDT is the mean down time is the statistical mean of the downtimes including
the supply downtime and administrative downtime.
In general availability of a system is a complex function of reliability, maintainability
and supply effectiveness
Maintenance of modern equipment and industry requires a healthy, balanced and rationalized
organization devoted to achieve the goals of the maintenance task. The organization required for
any system can be formed after careful study of the existing conditions and also the future
demands of the industry.
23. 23
MAINTENANCE ORGANIZATION
The tasks of the maintenance organization are as follows:
(i) Identification of organization roles pertaining to maintenance function
(ii) Determination of maintenance workload
(iii) Uniform distribution of total maintenance work to all the personal in the department
(iv) Identification and assignment of essential works to the various sections of the maintenance
department
(v) Proper knowledge about the technical expertise/experience of the workers deputed for the
particular job
(vi) Proper training of the staff of maintenance to meet the growing demands of the industry
and to catch up with the modern trends in maintenance
(vii) Designing the policies and procedures at an early stage to help the maintenance
department to achieve the goals of the industry.
24. 24
MAINTENANCE FUNCTIONS AND ACTIVITIES
The functions and activities of the maintenance organization are as follows:
(i) Identifying areas for implementation of preventive maintenance program
(ii) Making suitable arrangements for maintenance facilities for carrying out the
maintenance work properly
(iii) Planning and scheduling the total maintenance work
(iv) Ensuring proper and timely supply of spare parts
(v) Managing proper inventory control of materials spares and tools required for the
maintenance
(vi) Standardization of maintenance work
(vii) Implementing modifications to the existing equipment wherever possible
(viii) Assisting the purchase department in procuring materials Disbursement of
services such as water, electricity, steam, compressed air and other amenities required
to carryout the maintenance
(ix) Identification of obsolete and surplus equipment for replacement and disposal
(x) Designing the systematic way for disposal of equipment and for maintaining floor
space
(xi) Training of maintenance personnel
(xii) Analysis of future demands and forecast the role of maintenance activities
(xiii) Implementation safety norms and procedures
(xiv) Ensuring safety of personnel and equipment
25. 25
TYPES OF MAINTENANCE ORGANIZATION
The selection of a type of maintenance system will largely depends on the structure of an
industry. Maintenance organization can be broadly classified into three types as follows:
(i) Decentralized
This is suitable for large sized plants where inter unit communication is difficult to get.
In this type of organization, the maintenance is under the control of chief engineer of production
to ensure better understanding between the production and maintenance department.
(ii) Centralized
This is suitable for small units where unit communication is feasible. In this type of
organization, the maintenance is under the control of chief maintenance engineer. The
responsibilities and accountability is with the concerned department heads.
(iii) Partially Centralized
This is the modified version of centralized maintenance organization and suitable for
the industry where units are located at far away locations. In this type of organization, the
maintenance personal attached with production unit will carryout the routine maintenance
works. Scheduled maintenance works such as overhauls, planned maintenance work,
procurement of spare parts are under the control of chief maintenance engineer at the central
office. There are basically two at least two types of organization are followed in most of the
industries. They are Line Organization and Line staff Organization
26. 26
Line Organization
Line organization consists of a general foreman and a number of specialist foremen with their
team under them as shown in Figure. The specialist foremen execute maintenance work in their
respective areas while the general foreman supervises the total work under his control and
coordinates the various maintenance tasks carried out in the industry. This kind of structure is an
old type maintenance organization.
27. 27
Line Staff Organization
A few more staff members such as storekeeper and clerk are added to the line
organization to form the line staff organization structure as shown in Figure The advantage
lies in separating the maintenance work from the storekeeping and the role of clerk is to record
the maintenance activities. The recording of maintenance related activities helps the organization
to restructure the strategies adopted to achieve the objectives of maintenance.
28. 28
Maintenance functional organization
Maintenance functional organization is the structure based on craft concept. In this
Organization structure persons joined the organization as apprentices and elevated to higher
positions such as foreman after sufficient experience in their respective jobs. This
organization structure is based on the craft skills acquired through experience. There is no
formal training mechanism available at each stage of the organization. The recent trends in
maintenance management also favors this kind of functional based organization based on craft
skills. Fig. shows the maintenance functional organization in which few workers are placed
under each functional foreman.
29. 29
GENERAL ORGANIZATION OF MAINTENANCE DEPARTMENT
The general Organization structure of a maintenance department is shown in Figure
30. 30
MAINTENANCE ECONOMICS
LIFE CYCLE COST ANALYSIS
The factors to be considered in the purchase of equipment for industries include the cost, quality,
performance and maintenance requirements. Some balance is to be made between the capital cost
and operating cost of the equipment in finding the suitability of the equipment. The evaluation of
any equipment for purchase should be made by keeping into considerations that total cost incurred
by the equipment over a span of time say ten years.
Life cycle costing is the cost analysis for the equipment in an industry
that accounts the total cost of the equipment over a span of time
which includes the capital cost, operating cost and maintenance
costs.
This analysis is the integration of engineering, economic and financial strategies in relation to the
equipment to be purchased. The aim of life cycle costing is to ascertain the total cost of equipment
over the span of its entire life period.
Advantages of Life Cycle Costing
(i) Integration of engineering, economics and financial aspects lead to the way of robust metric for
the selection and purchase equipment required for the industry.
(ii) Reduced operating and maintenance cost of equipments due to cost analysis over span of time.
(iii) It leads to the selection of proper and economically viable equipment
31. 31
ESTIMATION OF ECONOMIC LIFE OF EQUIPMENT
The economic life of equipment depends on the maintenance and repair costs,
availability and operational efficiency. A plot of cumulative efficiency and
maintenance and repair cost per cumulative hours Vs operating hours of the equipment
to find the economic life of the equipment is shown in Figure
32. 32
MAINTENANCE COST
Budgets are allocated for all the activities in planning stage itself which
includes the maintenance cost. The cost of maintenance is difficult to measure due to
random nature of failures. The records on maintenance history may be useful in
determining the cost. The analysis of maintenance cost is helpful in taking a decision
regarding replacement of a machine or any of its components.
Component of Maintenance Cost
The maintenance cost is comprised of two factors:
(i) Fixed cost and (ii) Variable cost
(i). Fixed Cost
This includes the cost of support facilities including the maintenance staff.
(ii). Variable Cost
This includes the consumption of spare parts, replacement of components and
cost other facilities required to meet the requirements of maintenance.
33. 33
Factors Considered For Evaluation of Maintenance Cost
The evaluation of maintenance cost should consider the following factors:
(i) Cost of maintenance from the recorded data (past experience)
(ii) Level and requirements of maintenance
(iii) Cost of spare parts and materials
(iv) Cost of replacement of components and assemblies subjected wear and tear
(v) Accounting the number of breakdowns with their levels
(vi) Downtimes of the equipment for want of maintenance and repair
(vii) Penalty cost due to the loss of production
(viii) Cost of manpower involved
(ix) Cost of additional manpower requirements for emergency breakdown and
maintenance.
34. 34
MAINTENANCE BUDGET
The maintenance budget is used to set aside certain amount of money to meet the
expenditures incurred in achieving the objectives of maintenance.
The following are the types of maintenance budget
(i) Appropriation Budget
Budget used to allocate money for each activity independently.
(ii) Fixed Budget
Fixed used to allocate money for a specified period of time.
(iii) Variable Budget
Dynamic allocation of expenditure based on maintenance requirements
and activities.
35. 35
Factors to be considered in Preparation of Maintenance Budget
The factors to be considered in preparing the maintenance budget
(i) Data on failure, downtime cost due to equipment breakdown, cost of
damage, loss of production, penalty cost due to loss of production and replacement cost
(ii) Proper judgment of repair or replacement:
If the cost involved in operation of a machine is in increasing trend, a proper
judgment can be made for replacing the machine instead of frequent repairs
(iii) Comparison between in-house maintenance and hired maintenance :
The cost involved in hiring the maintenance personal outside the
organization to carry out the specific tasks of maintenance needs to be compared with
the cost
involved in using the available resources
(iv) Equipment overhaul periods - Overhaul schedule is to be carried out in
time that will improve the performance of equipment and may enhance its service life
(v) Cost of obsolescence - Expenses associated with fuel, oil,
wages and maintenance of older machines
Editor's Notes
INTRODUCTION TO THE CONCEPT OF PLANNING
Planning ensures the smooth operation of the system. For effective
working of any system, it is necessary to plan and schedule its activities.
The basic objectives of any planning task are to convert the concepts
into workable actions.
There are several approaches in planning which are necessary to
fulfill the objectives of organization. The planning in engineering
system is classified into three major approaches:
• Long range Planning
• Short range Planning and
• Planning for immediate activity
1.1.3.1. Long Range Planning
Long range planning refers to the planning spread over span of five
to ten years. In this type of planning the goals are set, strategies are
developed and operational programmes are devised for the period of
planning.
1.1.3.2. Short Range Planning
Short range planning is prepared by the concerned departments for
a relatively shorter period of time say one to two years.
1.1.3.3. Immediate Activity Planning
Immediate activity planning is a routine and is done at the working
level as and when required.
Maintenance Engineering
1.1.4. MAINTENANCE PLANNING
Maintenance planning is the task of organizing resources to carry out a
job satisfactorily at reasonable cost within a' specified period of time.
Maintenance Planning involves the assignment of jobs to the
maintenance crew. Job assignment must be done on the basis of proper
job scheduling of the maintenance work. The maintenance planning
should be careful designed in such a manner it is able to tackle the
emergency maintenance as well as ,to ensure that maintenance
workforce is fully utilized.
1.1.4.1. Objectives of Maintenance Planning
The most important objective of the maintenance system is the
maximization of availability of equipments and facilities so as to help in
achieving the ultimate goals of the organization. The following are the
objectives of planned maintenance activity:
(i) To achieve minimum breakdown and to keep the plant in
good working condition at the lowest possible cost
(ii) To ensure the availability of the machines and services in an
optimum working condition
(iii) To keep the Machines and other facilities in a condition to be
used to achieve the maximum profit without any interruption
or hindrance
(iv) To keep the time schedule of delivery to the customers or to
the sections for further processing
(v) To meet the availability requirements for critical equipments
(vi) To keep the maintenance costs as low as possible 'for non
critical equipments
(vii) To control the cost of maintenance related activities
(viii) To provide effective and trained supervision
INTRODUCTION TO THE CONCEPT OF PLANNING
Planning ensures the smooth operation of the system. For effective
working of any system, it is necessary to plan and schedule its activities.
The basic objectives of any planning task are to convert the concepts
into workable actions.
There are several approaches in planning which are necessary to
fulfill the objectives of organization. The planning in engineering
system is classified into three major approaches:
• Long range Planning
• Short range Planning and
• Planning for immediate activity
1.1.3.1. Long Range Planning
Long range planning refers to the planning spread over span of five
to ten years. In this type of planning the goals are set, strategies are
developed and operational programmes are devised for the period of
planning.
1.1.3.2. Short Range Planning
Short range planning is prepared by the concerned departments for
a relatively shorter period of time say one to two years.
1.1.3.3. Immediate Activity Planning
Immediate activity planning is a routine and is done at the working
level as and when required.
Maintenance Engineering
1.1.4. MAINTENANCE PLANNING
Maintenance planning is the task of organizing resources to carry out a
job satisfactorily at reasonable cost within a' specified period of time.
Maintenance Planning involves the assignment of jobs to the
maintenance crew. Job assignment must be done on the basis of proper
job scheduling of the maintenance work. The maintenance planning
should be careful designed in such a manner it is able to tackle the
emergency maintenance as well as ,to ensure that maintenance
workforce is fully utilized.
1.1.4.1. Objectives of Maintenance Planning
The most important objective of the maintenance system is the
maximization of availability of equipments and facilities so as to help in
achieving the ultimate goals of the organization. The following are the
objectives of planned maintenance activity:
(i) To achieve minimum breakdown and to keep the plant in
good working condition at the lowest possible cost
(ii) To ensure the availability of the machines and services in an
optimum working condition
(iii) To keep the Machines and other facilities in a condition to be
used to achieve the maximum profit without any interruption
or hindrance
(iv) To keep the time schedule of delivery to the customers or to
the sections for further processing
(v) To meet the availability requirements for critical equipments
(vi) To keep the maintenance costs as low as possible 'for non
critical equipments
(vii) To control the cost of maintenance related activities
(viii) To provide effective and trained supervision